Study on flange-constrained spinning process for hemispherical aluminum alloy part

Yu, Zhongqi; Zhao, Yixi; Du, Chenyang; Liu, Ruofan; Evsyukov, Sergey

doi:10.1016/j.jmatprotec.2019.116515

Cited by 14 publications

(7 citation statements)

References 22 publications

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“…In studies of spinning processes, FE simulation is an efficient method for investigation of the deformation characteristics of plastic forming processes and defect prediction [17][18][19][20] . The FE software Simufact.forming was used for DRSP simulations and was used in combination with experimental results to analyze and explain the deformation characteristics and parameter effects.…”

Section: Finite Element (Fe) Simulationmentioning

confidence: 99%

Study of dieless radial spinning for thick-walled cylindrical parts with external grooves

Liu

Jin

Rao

et al. 2021

Int J Adv Manuf Technol

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Thick-walled cylindrical parts with external grooves are common components in the automobile and aviation fields. Such components can be produced by pressing the outer surface of a spinning thick-walled aluminum alloy tube by the dieless radial spinning process. The forming characteristics in the spinning process and the effects of various process parameters on forming were studied by using orthogonal tests and finite element simulations. During the forming process, bulge and thickness reductions occur because of material flow. The results of an investigation of process parameter effects show that the stress yield ratio (ξ) had no significant effect on forming. However, the feed thickness ratio (η) and initial wall thickness of the tube (t0) crucially affected the forming quality (e.g., the heights of bulges and thickness reduction in the groove area). Thick-walled tubes presented different phenomena compared to the thin-walled. Keywords Thick-walled; dieless; spinning; orthogonal test; finite element; aluminum alloy Highlights of the research:1. The thick-walled cylindrical parts with external grooves were produced by the dieless radial spinning process.2. The effects of the process parameters on the forming quality were analyzed.3. The difference between the thick-walled tubes thin-walled tubes while spinning process was revealed. 4. A suggestion about the values of the parameters to obtain an eligible part were given.

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Section: Finite Element (Fe) Simulationmentioning

confidence: 99%

Study of dieless radial spinning for thick-walled cylindrical parts with external grooves

Liu

Jin

Rao

et al. 2021

Int J Adv Manuf Technol

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show abstract

“…Among them, friction coefficients between the blank-rollers and between the blank-mandrel were set as 0.02 and 0.2, respectively, as in literature. 48,49 In the FE model, the blank was defined as a deformed body and the meshing strategy for the blank (1/4) is shown in Figure 3. Four-node shell elements with reduced integration (S4R) were mainly used for the blank and triangular S3 shell elements were used as transition elements to control the element size of the circular blank at different radii in circumferential direction.…”

Section: Fe Model Constructionmentioning

confidence: 99%

Fracture prediction in spin forming of anisotropic metal sheets

Zheng

Zhan

et al. 2021

Proceedings of the Institution of Mechanical Engineers, Part C:

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Fracture often occurs in the spin forming process of thin-walled metal sheets, due to the limited fracture strain and local large plastic deformation of the sheets during the process. However, the accurate fracture prediction is a huge challenge due to the combinations of material anisotropy, complex deformation history and contact boundary conditions in the process. Though there are scattered uncoupled ductile fracture criteria proposed with various deformation mechanisms, reasons for their different fracture prediction abilities remain unclear. Thus in this study, eight popular uncoupled ductile fracture criteria i.e., Freudenthal, C-L, R-T, Brozzo, Oh, Oyane, MMC4 and DF2016, are embedded into an anisotropic constitutive model through VUMAT interface in the ABAQUS simulation software and then realized their fracture prediction in the spin forming process of an anisotropic metal sheet. The results show that the damage accumulation in the spin forming process occurs in a wide range of stress triaxiality, and the most damage accumulation occurs in the stress triaxiality range of 0–1/2. Furthermore, the eight fracture criteria have different prediction abilities in the process and a new deformation history related equivalent fracture strain is proposed to explain these differences. In addition, there exists the abnormal phenomenon that some simple damage models, as Oyane, Oh, etc. provide the more accurate fracture prediction ability than the complex and advanced MMC4 and DF2016 models in the process, and reasons for this phenomenon are explained.

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“…Spinning is a method that uses the movement of a rotary wheel to press the blank rotating with a mold. It causes continuous plastic deformation of metals and finally obtains the hollow rotation parts [ 10 ]. However, with the requirements of lightweight and high strength, spinning still has the following disadvantages: 1.…”

Section: Introductionmentioning

confidence: 99%

“…Due to the reciprocating action of the rotary wheel, the microstructure of the rocket nozzle is elongated. Therefore, the grain is easy to grow up abnormally after heating, which does not meet the requirements under high temperatures and pressure [ 10 ]. With the increasing difficulty of space exploration missions, the requirements for the rocket nozzle are becoming significantly stricter.…”

Section: Introductionmentioning

confidence: 99%

Theoretical Analysis and Verification on Plastic Deformation Behavior of Rocket Nozzle Using a Novel Tube Upsetting-Bulging Method

et al. 2023

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The rocket nozzle is one of the core components to ensure the safe flight of rockets. To overcome the problems of multi-step forming, the occurrence of defects, and severe plastic deformation in traditional technology, a novel forming method named tube upsetting-bulging (TUBG) is put forward. With the support of internal pressure, a tube is deformed with an upsetting and bulging process at the same time. The tube is thickened at the small end and thinned at the large end. A nozzle with sharply varying diameters can be obtained. A theoretical model of TUBG that considers wrinkles and rupture is built. The influence factors of internal pressure during TUBG are discussed. Experiments and simulation works are conducted to analyze the plastic deformation process of TUBG. Results show that mechanical properties and geometrical parameters have an obvious influence on critical internal pressure. The proposed theoretical model can be used to predict a forming zone without wrinkles, rupture, and severe strain values. A well-formed nozzle can be obtained using the predicted forming zone, which verifies the correctness of the theoretical analysis. It can be found that TUBG is a novel potential method to fabricate rocket nozzles with high efficiency and quality without defects.

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Study on flange-constrained spinning process for hemispherical aluminum alloy part

Cited by 14 publications

References 22 publications

Study of dieless radial spinning for thick-walled cylindrical parts with external grooves

Study of dieless radial spinning for thick-walled cylindrical parts with external grooves

Fracture prediction in spin forming of anisotropic metal sheets

Theoretical Analysis and Verification on Plastic Deformation Behavior of Rocket Nozzle Using a Novel Tube Upsetting-Bulging Method

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